Method of building



p 25, 1939- P. J. STOCKMAN 2,174,394

METHOD OF BUILDING Filed Sept. 16, 1938 P. J. ST OCKMAN METHOD OFBUILDING.

Sept. 26, 1939.

Filed Sept. 16, 1938 2 Sheets-Sheet 2 FIGZ. I

Patented Sept. 26, 1939 UNITED STATES PATENT OFFICE METHOD OF BUILDINGPeter J. Stockman, St. Louis, Mo.

Application September 16, 1938, Serial No. 230,225

1 Claim.

This invention relates to methods of building, and. with regard tocertain more specific features, to methods of building walls or the likefrom bricks and similar block-like units.

Among the several objects of the invention may be noted the provision ofa method of the class described whereby bricks, rubble stones, tile,terazzo, terra-cotta, and other block-like units may be laid up in a.precision manner, as in the building of a wall, without necessitatingskilled labor for the building; the provision of a method of the classdescribed which makes it possible'to lay brick and like material in amuch faster manher than heretofore possible, while at the same timepreserving or even improving the accuracy of the manner in which thebricks are laid up; the provision of a method of the class describedwhich employs mold apparatus of relatively simple and cheapconstruction, which apparatus may readily be moved from place to placeand reused many times during the course of the erection of a singlebuilding; and the provision of methods of the classdescribed which aresimple and economical. Other objects will be in part obvious and in partpointed out hereinafter.

The invention accordingly comprises the steps and sequence of steps, andfeatures of manipulation, which will be exemplified in the methodshereinafter described, and the scope of the application of which will beindicated in the following claim.

In the accompanying drawings, in which is illustrated one of variouspossible embodiments of the invention,

Fig. 1 is a perspective view of apparatus made ready for carrying outthe method of the present invention;

Fig. 2 is a vertical cross section demonstrating the use of theapparatus of Fig. 1 in the method of the present invention;

Figures 3, 4, 5 and 6 are elevations of certain striking tools; and,

Figure 7 is a view illustrating another use of the method of the presentinvention.

Similar reference characters indicate corresponding parts throughout theseveral views of the drawings.

Bricklaying as it is practiced today is a semiskilled trade; that is, itrequires a considerable amount of experience before a laborer canproperly lay bricks. The same is true to a large extent of the otherbuilding units of block-like type, such as rubble stones, tile, terazzo,terra-cotta, and like wall constructions. As a result of the requiredskill, the labor cost for such building operation is inordinately high.It is a primary object of the present invention to provide a method,with its accompanying apparatus, whereby the laying of brick and likematerials is reduced from a skilled laborers task to that of anunskilled laborer. At the same time, the method and apparatus of thepresent invention, far from sacrificing the accuracy of skilledbricklaying, make it possible for the bricks to be layed, even by anunskilled worker, with far greater accuracy than 10 heretofore possibleeven with great manual skill.

Since the method of the present invention, to a great extent, depends onthe design and construction of certain apparatus used in connection withthe method, said apparatus will first be 15 described. Broadly, theapparatus used in connection with the method of the present inventioncomprises a d'emountable mold, with which are associated certainU-shaped clamping devices for holding the mold in assembly, and certaingauge 20 or template tools or the like for use in connection with theerected mold in carrying out the method.

Referring now more particularly to Fig. 1, the mold proper comprisesparallel side-boards or elongated members I and 2. The lengths of the 25boards I andZ is immaterial. Their width should not ordinarily be muchgreater than the length of the human arm, and ordinarily two feet isabout the maximum width that can be handled with facility. The thicknessof the boards I and 30 2 depends largely upon the type of constructionto be carried out; ordinarily, one inch boards are satisfactory. It isimportant that the upper and lower long edges of the boards I and 2 besmooth, and parallel.

The mold boards I and 2 are held in assembly, in molding position, bymeans of a series of clamps or supports indicated generally by numeral3. The clamps 3 have sidewardly disposed leg members 4 and 5 and anupper cross bar 6. 40 Cross bar 6 is rigidly bolted or otherwise securedto the upper end of leg 4, as by angle iron plates 1 on each sidethereof. Leg 5, on the other hand, is not rigidly attached to the crossbar 6, but is pivoted thereto in the following manner: To each 45 sideof the free end of cross bar 6 is bolted a plate 8, the end of whichextends a suitable distance beyond, the end of cross bar 6. The plates 8are drilled near'their ends to receive a pin or bolt 9, which passesthrough a suitable hole 55 5 drilled through the upper end of leg 5. Aplurality of said holes ID are preferably provided in the upper end ofsaid leg 5, for purposes of adjustment hereinafter to be described. Inassembly, a suitable space; indicated by numeral l I, is 55 left betweenthe end of cross bar 6 and the upper side face of leg 5 so that said leg5 may pivot, to a limited extent, upon the pin 9.

Somewhat below the cross bar 6, a tie rod I2 extends across between thelegs 4 and 5. At its end extending through leg 4, the tie rod I2 is bentover, or otherwise headed, as indicated at numeral I3 (see Fig. 2),while at its opposite end the tie rod is threaded, as indicated atnumeral I4, to receive a wing-nut or the like I 5. By drawing up thewing-nut I5 on the threaded portion I4 of tie rod I2, the lower end oflegs 4 and 5 are brought closer together, to exert a clamping action,the pivoting of leg 5 on pin 9 permitting this movement.

At their lower extremities, the facing surfaces of legs 4 and 5 areprovided with removable spacing blocks I6.

Ordinarily mold boards I and 2 are not permanently affixed to the clamp3. However, if in a given job a unit length of mold may be usedrepeatedly to advantage, it then may become advisable to secure the moldboards I and 2 to the legs 4 and 5, respectively, as by nailing them inplace. Such securing does not interfere with the use of the mold, as awhole, in the subsequently described method.

It is usually sufficient that one clamp 3 be provided for each five orsix feet of length of the mold boards I and 2. However, the number andspacing of the clamps 3 is an arbitrary matter, and may be decided atthe time of carrying out the method of the invention to meet thepeculiar conditions then existing.

Fig 1 also illustrates the manner in which the apparatus may be used informing a corner or like mold. To form a corner, the mold board I isterminated flush with the front face of leg 4 of one of the clamps 3,and a similar mold board, indicated by numeral I1, is abutted in angularrelation to the end of the mold board I and the said face of the leg 4.The mold board 2, on the other hand, extends a suitable distance beyondleg 5. To the mold board 2 is then nailed a cleat or the like, indicatedby numeral I8, which forms a shoulder against which is seated the end ofa mold board I9 which is provided as a companion for the moldboard IT.The mold boards I! and I 9 are held in suitable spaced relationship bymeans of one or more clamps 3, as shown. This corner structure, it willreadily be seen, is easily demountable and can be made up readily from asecond mold assembly whenever the occasion arises.

The apparatus as thus described is used in the method of the presentinvention in the following manner, reference now being directed moreparticularly to Fig. 2:

Numeral 20 indicates the upper edge of a concrete or like foundationwall, or footing, or the like, that is provided for the building in theusual manner, prior to the commencement of the method of the presentinvention. It will be assumed, for present purposes, that the wall 20 isof the same width as the brick wall it is desired to build,

The mold apparatus is now clamped into position on the top of said wall20. The actual clamping surfaces are the inner, facing surfaces of thespacer blocks I6. The mold boards I and 2 are of the same thickness asthe blocks l6, so that when the wing nuts I5 are drawn up tight, theinner faces of said boards I and 2 form in effect continuations of theplanes of the side surfaces of the foundation wall 20. To assist inpositioning the mold boards properly, it is desirable to use a number ofspacing blocks 2| (see Fig. 1) of correct length, particularly if themold boards I and 2 are not rigidly secured to the clamps 3. The spacingblocks 2I hold the mold boards I and 2 apart, through the reaction ofthe sides of the legs 4 and 5 towards each other, The mold is positionedso that the upper edges of mold boards I and 2 are level, and parallelto the top surface of the foundation wall 20 (assumed likewise to belevel).

With the mold apparatus thus in position, a quantity of mortar is nowpoured in so that it forms a thin layer 22 on top of the foundation wall20. In order that said layer 22 may be of uniform thickness, and levelalong its upper surface, a template or tool 23 of the type shown in Fig,3 is now used. This tool 23 comprises a rectangular plate havingprojections 24 extending from the opposite sides of its upper edge. Touse the tool 23, the lower portion thereof is inserted between the moldboards I and 2, with the projections 24 resting upon the upper edges ofsaid mold boards. Said tool is then moved back and forth along the moldboards, and the lower edge 25 thereof constitutes a striking-01f meanswhich levels the layer of mortar 22. Fig. 1 shows the position, forexample, in which the tool 23 is placed for use.

After the layer 22 of mortar has thus been leveled off, an initialcourse of brick, indicated by numeral 26, is set in position on topthereof. The inner surfaces of mold boards I and 2 permit the accurate,quick positioning of the bricks of course 26 in their desired location,and no particular skill is needed in the placement of the bricks forthis reason.

After the bricks of the first course have thus all been set in position,an additional quantity of mortar is placed into the mold. The quantityin this instance is sufiicient not only to provide a top layer 21 ofmortar, but also to provide vertical layers of mortar, indicated bynumeral 28, between the individual bricks of the first course.

The top layer 21 is now struck off and leveled with a tool 23 of thetype indicated in Fig. 4. The tool 23 of Fig. 4 is identical to the toolof Fig. 3, with the exception that it is shorter, along its verticaldimension, by an amount equal to the thickness of one course of brickplus the desired thickness of the mortar layer 21,

After the first course 26 of brick has been laid, or the second course,it will clearly be seen that the spacing blocks 2| can be knocked outfrom position, as they are no longer needed. The spacing blocks 2| thusdo not interfere in any manner with the laying of the bricks, as saidlaying progresses.

Additional courses of brick are laid up in like manner, one after theother, using progressively shorter tools 23 (see Figs. 5 and 6) tostrike off or level the successive layers of mortar, until a course ofbrick (indicated in Fig. 2 by numeral 29) is laid, the upper surface ofwhich is above the edges of the mold boards I and 2. The wing nut I5 isthen loosened on the tie rod I2, thus disengaging the clamping faces ofblocks I6 from the foundation wall 20. The mold as a whole may theneasily be removed from the brick wall thus built.

As soon as the section of wall thus built has achieved sufficientrigidity, the mold is again clamped thereto, as shown in dotted lines inFig. 2, with the upper edges of blocks I 6 now level with the uppersurfaces of the top course 29 of brick. The laying of brick thenproceeds in the same manner 'as heretofore described, until the mold isagain filled. It will clearly be seen that the mold may be raised andreclamped in position as often as necessary, until the entire height ofthe wall is built.

Corners may easily be taken care of in the same manner, by using theconstruction shown at the left-hand end of Fig. 1. e

The numerous advantages of the method of the present invention as thusdescribed will now be apparent. In the first place, the positioning ofthe individual bricks in the courses is exceedingly accurate-far moreaccurate in fact, than can at any time be achieved by hand laying,inasmuch as each brick is positioned against a form or wall that ispre-established in accurate position. Then, too, the layers of mortarbetween courses of brick are all of uniform thickness, and accuratelypositioned, because of the provision of the tools 23 of accurate sizeand shape. Furthermore, the topmost course of brick for any one setup isprecisely level with, or parallel to, the bottom course, and thissituation is maintained throughout the entire height of the wall soconstructed. For example, precise horizontal leveling may be achieved byusing a spirit level or the like along the upper edges of the moldboards I and 2 as the apparatus is clamped into position, and evenimperfections in the level of the top surface of the foundation wall 20may thus be corrected in the initial setting of the apparatus. Ofprimary importance is the feature that no previous skill in bricklayingis needed for a man to build up a wall, using the method of the presentinvention, achieving all of the advantages of accuracy inherent in themethod of the present invention.

An advantage of the apparatus provided for by the method of the presentinvention is its adaptability to a variety of circumstances. In Fig. '7,for example, is indicated the manner in which the apparatus may be usedfor commencing the building of a wall on a footing, or foundation wall,indicated by numeral 30, that is wider than the desired width of thebrick wall. For this purpose, the pin 9 is removed from its originalposition and the leg of the clamp 3 is raised relative to the cross bar6, so that said pin 9 may be reinserted in the next lower hole IEI. Oneleg 5 of the clamp 3 is thus made shorter than the other leg 4. Thespacing block I6 is now removed from the lower end of the shorter leg 5.

The apparatus as thus modified is now set up on the upper surface of thefoundation wall 30 in the manner indicated in Fig. 7. Clamping block I6of the leg 4 is made level with the top surface of said foundation wall30, as in the Fig. 2 arrangement. Spacing blocks 2| are used to suitablyposition the mold boards I and 2. In order to hold the apparatus inposition on the foundation wall 30, however, since it is no longerclamped thereto, the leg 5 may be temporarily nailed or bolted orotherwise aflixed to a floor joist, for example, such as that indicatedby numeral M, which floor joist is almost invariably positioned insubstantially the proper location anyhow.

The first few courses of brick are then laid up in precisely the samemanner as set forth in connection with Fig. 2. After the mold is oncefilled, it is reassembled. in its normal, Fig. 2 manner, and subsequentlevels are built up in the same manner as heretofore described.

It will be noted that none of the relatively moving parts of theapparatus, such as the threads on the tie rod l2, or the pin 9 and itssupports, are positioned in a region with which one mortar or the likewill normally come in contact. This is particularly advantageous, as itmeans that the movable parts of the apparatus are not at all likely tojam from mortar accumulations. The only parts of the apparatus thatnormally come in contact with the mortar are parts that are not likelyto be injured thereby, in any event.

In view of the above, it will be seen that the several objects of theinvention are achieved and other advantageous results attained.

As many changes could be made in the above methods without departingfrom the scope of the invention, it is intended that all mattercontained in the above description or shown in the accompanying drawingsshall be interpreted as illustrative and not in a limiting sense.

I claim:

The method of constructing walls and the like from brick comprisingestablishing a mold having mold walls defining the wall to beconstructed, said mold walls having aligned upper guiding edges, andbeing of a depth at least equal to several courses of brick, placing alayer of mortar on the bottom of the interior of said mold and strikingsaid layer off to a level surface by inserting a suitably sized toolinto the mold, which tool has projections resting on the aforesaidedges, and moving said tool back and forth along said edges, positioninga first course of brick in the mold on top of said mortar layer,aligning the individual bricks of the course in position by abuttingthem against the mold walls, placing additional mortar in the mold ontop of the said course of brick, said additional mortar being sulficientin amount both to fill the vertical spaces between the bricks of thefirst course and to provide a second layer of mortar over the tops ofbricks of the first course, striking off said second layer of mortar toa level surface, with a tool similar to the aforementioned tool, and.thereafter repeating the brick positioning and mortar layer placingalternately until the mold is substantially filled.

PETER J. STOCKMAN.

